Gear Deburring Cutter with Distributed Edges for Longer Tool Life
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Solution Overview
Problem
Existing tools for deburring and chamfering workpiece gears face a conflict between low manufacturing costs and long tool life, as current solutions do not adequately address this compromise.
Innovation Solution
A tool with a large number of cutting edges, arranged around the tool rotation axis, is designed to reduce stress on individual edges, thereby extending tool life while maintaining low manufacturing costs. The cutting edges are distributed evenly and extend along the axis, allowing for efficient machining of workpiece edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a small number of cutting edges are used in the tool, then the manufacturing cost is reduced, but the tool life is shortened due to higher stress and wear on individual cutting edges
Solution Approach 1:
The tool is segmented into multiple cutting edges (at least three, preferably five to ten) distributed around the tool rotation axis. Each cutting edge engages a different workpiece tooth, distributing the machining load across multiple segments. This segmentation allows the tool to maintain low manufacturing costs while extending tool life through load distribution.
Solution Approach 2:
Each cutting edge is designed with specific local characteristics (cutting edge angle, radius, geometry) optimized for its specific engagement position. The cutting edges may have different geometries depending on their position around the tool, allowing each to perform its specific function optimally while maintaining overall cost-effectiveness.
2Duration of action of moving object
If a large number of cutting edges are used in the tool, then the tool life is extended due to reduced stress on individual edges, but the manufacturing cost increases
Solution Approach 1:
The tool is designed with more cutting edges than the minimum single-edge configuration, but not necessarily with an excessive number. The optimal range (three to ten edges) provides sufficient load distribution to extend tool life while avoiding the diminishing returns and increased complexity that would result from adding too many edges. This partial action approach balances tool life extension with manufacturing cost control.
Solution Approach 2:
Multiple cutting edges on the same tool perform the same deburring and chamfering function simultaneously on different workpiece teeth. This multi-functionality allows the tool to process multiple features in one operation, extending effective tool life without proportionally increasing manufacturing cost, as all edges are part of a single tool body.
3Device complexity
If cutting edges are concentrated at a single position, then the tool structure is simplified, but the machining efficiency is reduced due to limited simultaneous engagement
Solution Approach 1:
The cutting edges are distributed around the tool rotation axis, adding a circumferential dimension to the cutting edge arrangement. This dimensional change allows multiple cutting edges to engage different workpiece teeth simultaneously during rotation, significantly improving machining efficiency while maintaining relatively simple tool structure through regular geometric distribution.
Solution Approach 2:
Multiple cutting edges are merged into a single tool body, allowing them to function as one integrated machining element. The cutting edges work in unison during tool rotation, combining their cutting actions to efficiently process multiple workpiece teeth in sequence or parallel, thereby improving productivity without requiring multiple separate tools.
4Device complexity
If cutting edges extend only in the radial direction, then the tool design is simplified, but the ability to machine along the tooth length is limited
Solution Approach 1:
The cutting edges are extended not only in the radial direction but also in the axial direction (parallel to the tool rotation axis). This adds an axial dimension to the cutting edge geometry, enabling the cutting edges to engage and machine workpiece teeth along their length, thereby increasing machining coverage and versatility while maintaining straightforward tool design through linear edge extension.
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
Described and illustrated is a tool (1) for machining deburring and/or chamfering a workpiece toothing (3) comprising a plurality of workpiece teeth (4), with a plurality of cutting edges (28, 29) arranged distributed around a tool rotation axis (AWZ) of the tool (1) and each extending along the tool rotation axis (AWZ) for machining deburring and/or chamfering workpiece edges (9, 10, 11, 12), in particular end edges (9, 10, 11, 12), of the workpiece toothing (3) extending between a tooth flank (7, 8) and a face (5, 6) of a workpiece tooth (4). To improve the compromise between low manufacturing costs and long tool life, it is provided that the cutting edges (28, 29) are formed by tool teeth (18) of at least one tool toothing (14) of the tool (1).